Conventional anticorrosive coatings suffer from limitations of low solid content and rigorous surface pretreatment, posing environmental and cost challenges in field applications. In this study, a novel high-solid-content (>95%) epoxy-polysiloxane (Ep-PSA) ceramic metal coating was prepared that enables low-surface-treatment application. The originality lies in the synergistic combination of nano-sized ceramic powders, high-strength metallic powders, polysiloxane resin (PSA), and solvent-free epoxy resin (Ep), which polymerize through an organic–inorganic interpenetrating network to form a dense shielding layer. The as-prepared Ep-PSA coating system chemically bonds with indigenous metal substrate via Zn₃(PO₄)₂ and resin functionalities during curing, forming a conversion layer that reduces surface preparation requirements. Differentiating from existing high-solid coatings, this approach achieves superior long-term barrier properties, evidenced by |Z|_0.01Hz value of 9.64 × 10⁸ Ω·cm², after 6000 h salt spray exposure—four orders of magnitude higher than commercial 60% epoxy zinc-rich coatings (2.26 × 10⁴ Ω·cm², 3000 h salt spray exposure). The coating exhibits excellent adhesion (14.28 MPa) to standard sandblasted steel plates. This environmentally friendly, durable, and easily applicable composite coating demonstrates significant field application value for large-scale energy infrastructure.

Microbiologically influenced corrosion (MIC) accounts for approximately 20% of the total corrosion-related losses worldwide, causing significant economic damage each year, particularly in Marine environments. However, there are still no truly effective and eco-friendly protection solutions against MIC, among which the incomplete understanding of the microbial biofilm development on metallic surface is a key limitation. Using 16S rRNA and ITS sequencing, we studied bacterial and fungal communities in rust layer biofilm and seawater. The results showed that Proteobacteria, Cyanobacteria and Bacteroidota were the dominant bacterial phyla, and Ascomycota and Basidiomycota were the dominant fungal phyla both in the rust layer biofilm and seawater. Bacteria like Erythrobacter and Aquimarina, as well as fungi like Aspergillus and Acremonium were were notable microorganisms in the rust layer biofilm. Source analysis revealed differences between biofilm and seawater communities, with 23.08% bacterial and 21.48% fungal communities originating from seawater. Stochastic processes governed biofilm and seawater microbial communities, and network analysis showed coexistence and interaction among bacteria and fungi. IMPORTANCE: The composition and source analysis of bacterial and fungal communities in the rust layer and seawater were studied, and the interaction of bacteria and fungi in the rust layer was discussed for the first time. Based on these findings, we provided a framework to explain the observed characteristics of microbial communities in rust layer biofilm and presented key evidence supporting the relationship between different microbial structures and interactions with metal corrosion. These findings, from the perspective of microbial ecology, provide a theoretical foundation for studying microbial corrosion in marine environments.

Developing an environmentally friendly material with dual functionality of corrosion monitoring and inhibition is crucial for reducing economic losses. Herein, dual-function phytic acid carbon dots (PA-CDs) were prepared with a hydrothermal treatment method for corrosion monitoring and inhibition. The as-prepared PA-CDs exhibited a distinct color change from brown-yellow to wine-red immediately in the presence of OH⁻, and H⁺ can restore the color of the PA-CDs-OH⁻ system from wine-red to brown-yellow. Inspired by the above phenomenon, a visible RGB-based colorimetric sensor was fabricated by combining PA-CDs coatings with the self-made RGB-sensing device to detect OH⁻/H⁺ during metal corrosion. In addition, PA-CDs had excellent corrosion inhibitory properties for Q235 steel hanging sheets in hydrochloric acid solutions, and the corrosion inhibition efficiency reached 96.40%. The excellent corrosion monitoring and inhibition properties demonstrate the potential application of the PA-CDs in engineering practice.